Multiobjective and multi-physics topology optimization using an updated smart normal constraint bi-directional evolutionary structural optimization method

To date the design of structures using topology optimization methods has mainly focused on single-objective problems. Since real-world design problems typically involve several different objectives, most of which counteract each other, it is desirable to present the designer with a set of Pareto optimal solutions that capture the trade-off between these objectives, known as a smart Pareto set. Thus far only the weighted sums and global criterion methods have been incorporated into topology optimization problems. Such methods are unable to produce evenly distributed smart Pareto sets. However, recently the smart normal constraint method has been shown to be capable of directly generating smart Pareto sets. Therefore, in the present work, an updated smart Normal Constraint Method is combined with a Bi-directional Evolutionary Structural Optimization (SNC-BESO) algorithm to produce smart Pareto sets for multiobjective topology optimization problems. Two examples are presented, showing that the Pareto solutions found by the SNC-BESO method make up a smart Pareto set. The first example, taken from the literature, shows the benefits of the SNC-BESO method. The second example is an industrial design problem for a micro fluidic mixer. Thus, the problem is multi-physics as well as multiobjective, highlighting the applicability of such methods to real-world problems. The results indicate that the method is capable of producing smart Pareto sets to industrial problems in an effective and efficient manner.     

Diffusion-based microalloying of aluminium alloys by powder metallurgy and reaction sintering

A diffusion-based technique of microalloying aluminium powder metallurgy products was examined to expand the range of feasible alloying additions. Thermodynamic calculations and diffusion rates for several elements suggested that tin and silver were the most promising; these elements were successfully alloyed into AA 2014 on both a macroscopic and a microscopic scale. The final microstructures were examined using X-ray diffraction, X-ray mapping and energy-dispersive electron probe microanalysis. Silver additions were homogeneous throughout the alloy microstructure, whereas tin was concentrated in intergranular regions only. The results suggested that the technique was viable for a variety of microalloying elements. Also, the extent of alloying was predicted reasonably well using a mathematical mass balance model.     

X-ray photoelectron spectroscopy (XPS) investigation of the surface film on magnesium powders

Magnesium (Mg) and its alloys are attractive for use in automotive and aerospace applications because of their low density and good mechanical properties. However, difficulty in forming magnesium and the limited number of available commercial alloys limit their use. Powder metallurgy may be a suitable solution for forming near-net-shape parts. However, sintering pure magnesium presents difficulties due to surface film that forms on the magnesium powder particles. The present work investigates the composition of the surface film that forms on the surface of pure magnesium powders exposed to atmospheric conditions and on pure magnesium powders after compaction under uniaxial pressing at a pressure of 500 MPa and sintering under argon at 600 °C for 40 minutes. Initially, focused ion beam microscopy was utilized to determine the thickness of the surface layer of the magnesium powder and found it to be ~10 nm. The X-ray photoelectron analysis of the green magnesium sample prior to sintering confirmed the presence of MgO, MgCO(3)·3H(2)O, and Mg(OH)(2) in the surface layer of the powder with a core of pure magnesium. The outer portion of the surface layer was found to contain MgCO(3)·3H(2)O and Mg(OH)(2), while the inner portion of the layer is primarily MgO. After sintering, the MgCO(3)·3H(2)O was found to be almost completely absent, and the amount of Mg(OH)(2) was also decreased significantly. This is postulated to occur by decomposition of the compounds to MgO and gases during the high temperature of sintering. An increase in the MgO content after sintering supports this theory.     

The effects of Ni3Al binder content on the electrochemical response of melt-infiltration processed TiC–Ni3Al cermets

TiC–Ni₃Al samples were successfully fabricated with varying amounts of the Ni₃Al intermetallic binder (alloy IC-50), ranging from 10 to 40?wt-%, through a simple melt-infiltration method. Each sample was then tested to determine the degree of resistance of that composition to electrochemical corrosion in an aqueous solution containing 3.5?wt-% NaCl, using a range of testing procedures including open-circuit potential, potentiodynamic polarisation and cyclic polarisation. Results indicate that the lowest binder content results in greater potential to resist corrosion. It is demonstrated that the Ni₃Al binder undergoes dissolution for the examined conditions, which was confirmed through the high amount of Al and Ni in the electrolyte solutions following testing. It was also confirmed from the electrochemical experiments and the SEM that localised corrosion was visible.     

The electrodeposition of improved molybdenum coatings from molten salts by the use of electrolyte additives

The electrodeposition of molybdenum from molten chlorides has been investigated in two electrolyte systems: KCl–K₃MoCl₆ at a temperature of 800°C and LiCl–KCl–K₃MoCl₆ at a temperature of 400°C. With the goal of improving the surface quality of the deposits, a search was conducted for electrolyte additives that would act as leveling agents. Activated alumina proved beneficial for deposits produced in the high temperature melt but had little or no effect on deposits generated at low temperatures. Molybdenum disulfide adversely affected the deposits by promoting the growth of surface irregularities.     

On enhancing the mechanical properties of aluminum P/M alloys

Sintered aluminum alloys are an attractive material for the automobile industry, both because of the low specific gravity and high strength-to-weight ratio of aluminum itself, and the fabrication advantages associated with a powder metallurgy process. However, properties such as impact, stiffness, corrosion and wear resistance are often poor, thereby restricting the widespread use of these materials. Recent work by the authors has shown that hardness, wear resistance and tensile properties of a P/M Al–Cu–Mg ternary master alloy can be improved using a novel diffusion/supersolidus liquid phase sintering process. Improvements were due to in-situ microalloying during sintering, in particular, the influence of Ag and Sn. To complement this work, the present investigation addresses the response of a commercial alloy, AA2014, to the microalloying process. Results show that sintered densities for the commercial alloy were relatively unaffected by the presence of either Ag or Sn, and were superior to the ternary master alloy. Hardness and tensile properties were also improved relative to those obtained for the ternary, and were comparable to wrought 2014. Examination of final microstructure of Ag modified AA2014 using TEM showed the presence of Ω as the principal precipitate, but only after extended sintering times. This particular precipitate is believed to contribute to enhanced hardness. The apparent absence of Ω for short sintering times was due to the presence of silicon in the commercial product. However, the corrosion behavior of the P/M AA2014 was superior to the wrought product and thus the process is presented as a potential P/M alternative to using ingot metallurgy techniques for microalloying.